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Modeling the Effects of Tool Pin Configurations and Friction Stir Processing Parameters on Tungsten Inert Gas Welded Dissimilar Aluminum Alloy Joints

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Abstract

The primary focus of this investigation is to examine the impact of friction stir processing (FSP) parameters on the tungsten inert gas (TIG) welded dissimilar AA6061-T6 and AA7075-T6 joints. Tool spindle speed, feed rate, tilt angle, and tool pin configuration were selected as input processing variables. A regression model was built using a central composite rotatable design matrix (CCRD) and response surface methodology (RSM) to forecast the mechanical features such as ultimate tensile strength (UTS), percentage elongation (PE), microhardness (MH), and residual stress (RS). Analysis of variance (ANOVA) was used to estimate the adequacy of the built-up models and identify significant terms. The results revealed that the tool pin configuration was found to be the most influential processing parameter relative to other parameters. The TIG + FSP joint fabricated with cylindrical threaded with triflat faces (THF) pin configuration has the highest mechanical properties and low residual stresses. The TIG + FSP joint showed an optimal UTS of 279.93 MPa, a PE of 20.92%, an MH of 115.42 HV, and a RS of 19.95 MPa when using a tool spindle speed of 1106.39 rpm, a feed rate of 45.79 mm/min, a tilt angle of 2.00 degrees, and a THF pin configuration. TIG joints exhibited brittle failure because of the rough cleavage facet and macro voids, while TIG + FSP joints exhibited brittle failure due to fine dimples and no voids. Electron backscatter diffraction showed that TIG + FSP welding produced ultrafine grains and significant grain boundary strengthening compared to TIG joints. Pole figures showed some recrystallization \({\text{A}}_{1}^{*}\)/\({\text{A}}_{2}^{*}\) and A/\(\stackrel{\mathrm{-}}{\text{A}}\) textures in the TIG joint at the FZ center, whereas the TIG + FSP joint exhibited significant shear deformation B/\(\overline{\text{B}}\) and C textures at the SZ center. Moreover, the intensity of texture in the TIG joint was only 3.02, while it was 10.34 in the TIG + FSP joint, indicating that significant texture strengthening occurred after FSP.

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Acknowledgments

The authors would like to thank Prof. Indradev Samajdar, Department of Metallurgical Engineering and Materials Science, Indian Institute of Technology Bombay, for facilitating the EBSD characterization and Prof. Qasim Murtaza, Department of Mechanical Engineering, Delhi Technological University, Delhi, for assisting with the residual stress characterization of the welded samples.

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  1. Department of Mechanical Engineering, National Institute of Technology Patna, Bihar, 800005, India

    Md Saquib Bin Reyaz & Amar Nath Sinha

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Reyaz, M.S.B., Sinha, A.N. Modeling the Effects of Tool Pin Configurations and Friction Stir Processing Parameters on Tungsten Inert Gas Welded Dissimilar Aluminum Alloy Joints. J. of Materi Eng and Perform (2024). https://doi.org/10.1007/s11665-024-09444-0

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